Abstract
Powder bed 3D printing can be applied to sandcasting mold manufacturing to ensure high quality and economy through process innovation. In this study, refractory alumina cement was used as an aqueous binder to ensure high-temperature thermal stability to minimize the addition of organic matter to reduce gas generation. In addition, spherical silica sand, the study material, was selected to a size of 30 µm to improve the casting mold resolution. To improve the surface quality through the post-treatment process, we confirmed the change in the surface roughness of the mold depending on the surface treatment of colloidal silica and the presence or absence of heat treatment, and finally made the mold through actual casting. Changes in the surface roughness and flowability of the cast body after mold post-treatment were confirmed. For aluminum castings, the shrinkage rate and surface roughness were confirmed in a box-shaped mold via gravity casting, and the flowability of the molten metal in the mold was confirmed in a hand-shaped mold. There was a change in the roughness and porosity of the mold, owing to the post-treatment, and the influence of the surface roughness and flowability of the cast body during actual casting was confirmed.
Highlights
Metal casting has been steadily researched and developed in today’s machinery and manufacturing fields as a method of pouring molten metal in which aluminum, cast iron, steel, special steel, etc. are melted into a mold to obtain the desired shape and characteristics [1]
A high temperature cast refractory cement, was used as a binder, and a 4000 mesh (4 μm) size that can be applied to 30 μm spherical silica sand was selected
The casting sand made of cement mixed sand was manufactured as a mold through the powder bed 3D printing process to secure the surface resolution, and, at the same time, it was confirmed that the casting quality was improved by securing the gas permeability and surface smoothness of the molding sand
Summary
Metal casting has been steadily researched and developed in today’s machinery and manufacturing fields as a method of pouring molten metal in which aluminum, cast iron, steel, special steel, etc. are melted into a mold to obtain the desired shape and characteristics [1]. Metal casting has been steadily researched and developed in today’s machinery and manufacturing fields as a method of pouring molten metal in which aluminum, cast iron, steel, special steel, etc. The most traditional method, sand casting, has undergone many developments over a long history of 4000 years, and still occupies a large share in the modern casting market [2]. It is easy to apply to sand casting. Products applied to existing organic binders, inorganic binders, and cement binders have been developed. It is notable in the casting market because mold making for large products is possible in an automatic process [3]
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